Engine Mechanical (Service Information): Diagnosis — Engine Mechanical (Service Information) — Mechanical

ON-VEHICLE INSPECTION [05/2013 - ]

HINT

The type of ignition switch used on this model differs according to the specifications of the vehicle. For the expressions listed in this section, refer to the "Ignition Switch Expressions" precaution. Refer to PRECAUTION [05/2013 - ] .

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Scheme 25: ON-VEHICLE INSPECTION [05/2013 - ]

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INSPECT VALVE LASH ADJUSTER ASSEMBLY NOISE Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then perform the inspection above again. If any defects or problems are found during the inspection above, perform a lash adjuster inspection See step 2 .
INSPECT IGNITION TIMING Warm up and stop the engine. When using the Techstream: Connect the Techstream to the DLC3. Start the engine and idle it. Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / IGN Advance. Standard ignition timing 5 to 15° BTDC @ idle HINT: Refer to the Techstream operator's manual for further details. If the ignition timing is not as specified, check the valve timing. When not using the Techstream: Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder. NOTE: Use a timing light that detects primary signals. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST: 09843-18040 TEXT IN ILLUSTRATION *a Front view of DLC3 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. When checking the ignition timing, the transmission should be in neutral. Using a timing light, check the ignition timing. Standard ignition timing 8 to 12° BTDC @ idle Remove SST from the DLC3. Check the ignition timing. Standard ignition timing 5 to 15° BTDC @ idle If the ignition timing is not as specified, check the valve timing. Check that the ignition timing advances immediately when the engine speed is increased. Disconnect the timing light from the engine.
INSPECT ENGINE IDLE SPEED Warm up and stop the engine. When using the Techstream: Connect the Techstream to the DLC3. NOTE: Switch off all accessories and the A/C before connecting the Techstream. Race the engine at 2500 rpm for approximately 90 seconds. Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / Engine Speed. Standard Idle Speed Item Specified Condition for Manual Transaxle 600 to 700 rpm for Automatic Transaxle 680 to 780 rpm HINT: Refer to the Techstream operator's manual for further details. NOTE: When checking the idle speed, the transmission should be in neutral. If the idle speed is not as specified, check the air intake system. Disconnect the Techstream from the DLC3. When not using the Techstream: Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3. SST: 09843-18030 TEXT IN ILLUSTRATION *a Front view of DLC3 NOTE: Confirm the terminal number before connecting the probe. Connecting the wrong terminals can damage the engine. Race the engine at 2500 rpm for approximately 90 seconds. Check the idle speed. Standard idle speed (Transmission in neutral) 600 to 700 rpm If the speed is not as specified, check the air intake system. Disconnect the tachometer probe from the DLC3.
INSPECT COMPRESSION Warm up and stop the engine. Check for DTCs. Refer to «DTC CHECK / CLEAR [05/2013 - 01/2014]»(ref-615120-S02653872462014050900000). Remove the 4 spark plugs. Refer to «REMOVAL [05/2013 - ]»(ref-615228-S33820474432014050900000). Disconnect the 4 fuel injector connectors. Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. Standard compression pressure 1450 kPa (14.7 kgf/cm 2, 210 psi) or higher Minimum pressure 980 kPa (9.9 kgf/cm 2, 142 psi) Difference between each cylinder 200 kPa (2.0 kgf/cm 2, 29 psi) or less HINT: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. If the cylinder compression is low in one or more cylinders, pour a small amount of engine oil into the cylinder with low compression through its spark plug hole. Then inspect the cylinder compression pressure again. HINT: If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore is worn or damaged. If the pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket. Connect the 4 fuel injector connectors. Install the 4 spark plugs. Refer to «INSTALLATION [05/2013 - ]»(ref-615228-S07692022022014050900000). Clear the DTCs. Refer to «DTC CHECK / CLEAR [05/2013 - 01/2014]»(ref-615120-S02653872462014050900000).
INSPECT CO/HC HINT: This check determines whether or not the idle CO/HC complies with regulations. Start the engine. Keep the engine speed at 2500 rpm for approximately 180 seconds. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling. Immediately check the CO/HC concentration at idle and at 2500 rpm. HINT: When performing the 2-mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check the air fuel ratio sensor. Refer to «INSPECTION [05/2013 - ]»(ref-615228-S25292060302014050900000) and heated oxygen sensor. Refer to «INSPECTION [05/2013 - ]»(ref-615228-S00484029412014050900000) operation. See the table below for possible causes, and then inspect and correct the applicable causes if necessary. CO HC Symptom Causes Normal High Rough idle 1. Faulty ignition Incorrect timing Plugs are contaminated or shorted, or gaps are defective 2. Leaky intake and exhaust valves 3. Leaky cylinder Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks PCV hose Intake manifold Throttle body Brake booster line 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI system Faulty pressure Defective engine coolant temperature sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty mass air flow meter sensor

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Scheme 27: ILLUSTRATION

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Scheme 28: ON-VEHICLE INSPECTION [05/2013 - ]

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INSPECT FAN AND GENERATOR V BELT Check the belt for wear, cracks or other signs of damage. If any of the following defects is found, replace the fan and generator V belt. The belt is cracked. The belt is worn out to the extent that the cords are exposed. The belt has chunks missing from the ribs. Check that the belt fits properly in the ribbed grooves. TEXT IN ILLUSTRATION *a CORRECT *b INCORRECT HINT: Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly.
INSPECT V-RIBBED BELT TENSIONER ASSEMBLY Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the V-ribbed belt tensioner.

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Scheme 30: REMOVAL [05/2013 - ]

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DISCONNECT FRONT FENDER LINER RH Remove the 2 screws and clip and disconnect the front fender liner.
REMOVE REAR ENGINE UNDER COVER RH Remove the 5 clips and rear engine under cover RH.
REMOVE FAN AND GENERATOR V BELT Attach a wrench to the hexagonal portion of the belt tensioner as shown in the illustration, rotate the belt tensioner clockwise, and remove the V belt.

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Scheme 32: INSTALLATION [05/2013 - ]

INSTALL FAN AND GENERATOR V BELT Set the V belt onto each part as shown in the illustration, except the engine water pump pulley. TEXT IN ILLUSTRATION *1 Belt Tensioner *2 Generator *3 Engine Water Pump *4 Cooler Compressor *5 Crankshaft Loosen the V belt by turning the belt tensioner clockwise. Set the V belt onto the engine water pump pulley. NOTE: Make sure that the belt is attached to each pulley. In particular, make sure that the belt is securely fitted into the grooves of the crankshaft pulley.
INSTALL REAR ENGINE UNDER COVER RH Install the under cover RH with the 5 clips.
CONNECT FRONT FENDER LINER RH Connect the front fender liner with the 2 screws and clip.

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Scheme 33: ILLUSTRATION

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Scheme 35: ILLUSTRATION

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Scheme 36: REMOVAL [05/2013 - 01/2014]

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DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [05/2013 - 01/2014]»(ref-615109-S22240423792014050900000).
REMOVE FRONT WHEEL RH
DISCONNECT FRONT FENDER LINER RH See step 8
REMOVE REAR ENGINE UNDER COVER RH See step 2
REMOVE AIR CLEANER CAP SUB-ASSEMBLY. Refer to «REMOVAL [05/2013 - 01/2014] - Step 2»(ref-615228-S13732942022014050900000)
REMOVE AIR CLEANER CASE SUB-ASSEMBLY. Refer to «REMOVAL [05/2013 - 01/2014] - Step 3»(ref-615228-S13732942022014050900000)
DISCONNECT ENGINE WIRE Disconnect the connectors and clamps, remove the bolts and nuts and disconnect the engine wire from the engine.
REMOVE IGNITION COIL ASSEMBLY. Refer to «REMOVAL [05/2013 - ] - Step 1»(ref-615228-S28016964092014050900000)
REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY. Refer to «REMOVAL [05/2013 - 01/2014] - Step 4»(ref-615225-S17239415012014050900000)
REMOVE CRANKSHAFT POSITION SENSOR. Refer to «REMOVAL [05/2013 - ] - Step 2»(ref-615228-S27526407822014050900000)
SEPARATE RADIATOR RESERVE TANK ASSEMBLY Remove the 2 bolts and separate the radiator reserve tank assembly.
SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover are aligned. TEXT IN ILLUSTRATION *1 Paint Mark *2 Matchmark *3 Timing Notch Check that each matchmark of the camshaft timing gear and camshaft timing exhaust gear are aligned with each matchmark located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing exhaust gear.
REMOVE TIMING CHAIN COVER PLATE Remove the 4 bolts, timing chain cover plate and gasket.
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Turn the crankshaft approximately 10° clockwise. Turn the crankshaft approximately 10° counterclockwise. Align the holes of the stopper plate and tensioner, and insert a pin into the stopper plate hole to lock the tensioner. TEXT IN ILLUSTRATION *1 Pin Turn the crankshaft approximately 10° clockwise. Remove the 2 bolts, chain tensioner and gasket. NOTE: Make sure not to drop the gasket inside the timing chain cover. Turn the crankshaft approximately 10° counterclockwise.
REMOVE TIMING CHAIN GUIDE See step 12
REMOVE TIMING CHAIN COVER TIGHT PLUG See step 23
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY Hold the hexagonal portion of the camshaft with a wrench and remove the bolt from the camshaft. NOTE: Be careful not to damage the cylinder head or spark plug tube with the wrench. Separate the camshaft timing gear assembly from the camshaft. Remove the timing chain from the camshaft timing gear assembly, and turn the camshaft timing gear assembly approximately 180°. TEXT IN ILLUSTRATION *a Narrow *b Wide Remove the camshaft timing gear assembly. NOTE: Do not disassemble the camshaft timing gear.
REMOVE CAMSHAFT BEARING CAP Using several steps, remove the 11 bearing cap bolts in the sequence shown in the illustration. Using several steps, remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps. HINT: Arrange the removed parts in the correct order.
REMOVE NO. 1 CAMSHAFT Remove the No. 1 camshaft from the camshaft housing.
REMOVE NO. 2 CAMSHAFT Hold up the chain and remove the No. 2 camshaft from the camshaft housing. Suspend the chain with a string or equivalent as shown in the illustration. NOTE: Be careful not to drop the chain inside the timing chain cover.
REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Remove the flange bolt and camshaft timing exhaust gear assembly. NOTE: Do not disassemble the camshaft timing exhaust gear.
REMOVE OIL CONTROL VALVE FILTER See step 37
REMOVE NO. 1 CAMSHAFT BEARING See step 39
REMOVE NO. 2 CAMSHAFT BEARING See step 40

INSPECTION [01/2014 - ]

INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand and check that it turns smoothly. If the roller does not turn smoothly, replace the valve rocker arm sub-assembly.
INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the adjuster free from dirt and foreign matter. Use only clean engine oil. Place the lash adjuster into a container full of new engine oil. TEXT IN ILLUSTRATION *1 Taper Part *2 Plunger *3 Low Pressure Chamber *4 Check Ball *5 High Pressure Chamber *a CORRECT *b INCORRECT Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger. SST: 09276-75010 Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times. Check the movement of the plunger and bleed air. OK Plunger moves up and down. NOTE: When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers. OK Plunger can be pressed 3 times. If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.
INSPECT CAMSHAFT OIL CLEARANCE NOTE: Do not turn the camshafts. Clean the bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each of the camshaft journals. TEXT IN ILLUSTRATION *1 Plastigage Install the camshaft bearing caps See step 11 . Install the camshaft housing sub-assembly See step 12 . Remove the camshaft bearing caps See step 20 . Measure the Plastigage at its widest point. Standard Oil Clearance Item Specified Condition Intake No. 1 journal 0.035 to 0.072 mm (0.00137 to 0.00283 in.) Exhaust No. 1 journal 0.049 to 0.086 mm (0.00193 to 0.00339 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Maximum Oil Clearance Item Specified Condition Intake No. 1 journal 0.085 mm (0.00335 in.) Exhaust No. 1 journal 0.095 mm (0.00374 in.) Other journals 0.085 mm (0.00335 in.) TEXT IN ILLUSTRATION *1 Plastigage *2 No. 1 Journal *3 Other Journals If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
INSPECT CAMSHAFT THRUST CLEARANCE See step 8
INSPECT CAMSHAFT Inspect the camshaft runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout 0.03 mm (0.00118 in.) If the circle runout is more than the maximum, replace the camshaft sub-assembly. HINT: Check the oil clearance after replacing the camshaft. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height Item Specified Condition Intake 44.163 to 44.305 mm (1.739 to 1.744 in.) Exhaust 44.144 to 44.286 mm (1.738 to 1.744 in.) Minimum Cam Lobe Height Item Specified Condition Intake 44.013 mm (1.733 in.) Exhaust 43.996 mm (1.732 in.) If the cam lobe height is less than the minimum, replace the camshaft sub-assembly. Inspect the camshaft journals. Using a micrometer, measure the journal diameter. Standard Journal Diameter Item Specified Condition No. 1 journal 34.449 to 34.465 mm (1.356 to 1.357 in.) Other journals 22.959 to 22.975 mm (0.904 to 0.905 in.) If the journal diameter is not as specified, check the oil clearance.
INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Align the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear and attach the gear to the camshaft. TEXT IN ILLUSTRATION *1 Pin Hole *2 Knock Pin Check that there is no clearance between the camshaft timing gear and camshaft flange. TEXT IN ILLUSTRATION *1 Camshaft Timing Gear *2 Clearance *3 Flange *4 No Clearance *a INCORRECT *b CORRECT Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear by hand. NOTE: Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged. Check the lock of the camshaft timing gear. Make sure that the camshaft timing gear is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. Clean the camshaft journal with non-residue solvent. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. TEXT IN ILLUSTRATION *1 Retard Side Path *2 Advance Side Path *3 Port A *4 Knock Pin *a Open *b Closed Rubber Vinyl Tape HINT: There are 4 oil paths in the grooves of the camshaft. Plug three of the paths with pieces of rubber. Open a hole at port A shown in the illustration. While applying compressed air at approximately 200 kPa (2.0 kgf/ cm 2 , 29 psi) to the oil path, forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise). WARNING: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. NOTE: Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again. HINT: The camshaft timing gear assembly may be turned in the advance direction without applying any force. If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult. Check for smooth rotation. Turn the camshaft timing gear within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE: Do not allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again. Remove the vinyl tape and pieces of rubber from the camshaft. Remove the bolt and camshaft timing gear.
INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Align the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear and attach the gear to the camshaft. TEXT IN ILLUSTRATION *1 Pin Hole *2 Knock Pin Check that there is no clearance between the camshaft timing exhaust gear and camshaft flange. TEXT IN ILLUSTRATION *1 Camshaft Timing Exhaust Gear *2 Clearance *3 Flange *4 No Clearance *a INCORRECT *b CORRECT Fix the camshaft in place by hand, and then install the installation bolt of the camshaft timing exhaust gear by hand. Check the lock of the camshaft timing exhaust gear. Make sure that the camshaft timing exhaust gear is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. Clean the camshaft journal with non-residue solvent. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path *3 Knock Pin *a Open *b Closed Rubber Vinyl Tape HINT: There are 4 oil paths in the grooves of the camshaft. Plug 2 paths with pieces of rubber. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration. Apply compressed air at approximately 200 kPa (2.0 kgf/cm 2 , 29 psi) to the two open paths (the advance side path and retard side path). TEXT IN ILLUSTRATION *1 Retard Side Path *2 Advance Side Path NOTE: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path. TEXT IN ILLUSTRATION *1 Retard Side Path *2 Advance Side Path *3 Hold Pressure *4 Decompress HINT: The lock pin is released and the camshaft timing exhaust gear turns in the retard direction. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear within its movable range (21.5 to 23.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear locks at the most advanced position. Remove the vinyl tape and pieces of rubber from the camshaft. Remove the bolt and camshaft timing gear.
INSPECT CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation 137.7 mm (5.42 in.) TEXT IN ILLUSTRATION *1 Measuring Area HINT: Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the chain sub-assembly.
INSPECT CRANKSHAFT TIMING SPROCKET Wrap the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter together with the chain. Minimum sprocket diameter (with chain) 59.94 mm (2.36 in.) If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket. HINT: The vernier caliper must contact the chain rollers for the measurement.
INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate counterclockwise to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the No. 1 chain tensioner assembly.
INSPECT CHAIN TENSIONER SLIPPER Measure the depth of wear of the chain tensioner slipper. Maximum depth 1.0 mm (0.0394 in.) TEXT IN ILLUSTRATION *1 Depth If the depth is more than the maximum, replace the chain tensioner slipper.
INSPECT NO. 1 CHAIN VIBRATION DAMPER Measure the depth of wear of the chain vibration damper. Maximum depth 1.0 mm (0.0394 in.) TEXT IN ILLUSTRATION *1 Depth If the depth is more than the maximum, replace the No. 1 chain vibration damper.
INSPECT TIMING CHAIN GUIDE Measure the depth of wear of the timing chain guide. Maximum depth 1.0 mm (0.0394 in.) TEXT IN ILLUSTRATION *1 Depth If the depth is more than the maximum, replace the timing chain guide.
INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the No. 1 balance shaft back and forth. Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly.
INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the No. 2 balance shaft back and forth. Standard thrust clearance 0.05 to 0.09 mm (0.00197 to 0.00354 in.) Maximum thrust clearance 0.09 mm (0.00354 in.) If the thrust clearance is more than the maximum, replace the engine balancer assembly.
INSPECT BALANCE SHAFT BACKLASH Fix the No. 2 balance shaft in place, and then, using a dial indicator, measure the backlash of the No. 1 and No. 2 balance shafts as shown in the illustration. Standard backlash 0.04 to 0.17 mm (0.00154 to 0.00669 in.) Maximum backlash 0.17 mm (0.00669 in.) TEXT IN ILLUSTRATION *a Fix in place NOTE: Measure at 3 or more areas around the circumference of the No. 1 and No. 2 balance shafts. If the backlash is more than the maximum, replace the engine balancer assembly.
INSPECT CYLINDER HEAD BOLT Using a vernier caliper, measure the diameter of the elongated thread at the measuring point. Measuring point 106 mm (4.17 in.) Standard diameter 10.85 to 11.00 mm (0.427 to 0.433 in.) Minimum diameter 10.6 mm (0.417 in.) TEXT IN ILLUSTRATION *1 Measuring Point If the diameter is less than the minimum, replace the cylinder head bolt. HINT: If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the smallest diameter.
INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the surface that contacts the cylinder head. Maximum warpage 0.7 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold.

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Scheme 54: REASSEMBLY [05/2013 - 01/2014]

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INSTALL STIFFENING CRANKCASE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic-faced hammer, tap in 2 new ring pins until they stop. Standard protrusion height 4.3 to 5.3 mm (0.169 to 0.209 in.) TEXT IN ILLUSTRATION *1 Protrusion Height
INSTALL STIFFENING CRANKCASE STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. TEXT IN ILLUSTRATION *A Front Side *B Lower Side Using an E5 and E8 "TORX" socket wrench, install the stud bolts. for stud bolt A Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for stud bolt B Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)
INSTALL ENGINE BALANCER ASSEMBLY Check that the alignment marks of the balance shaft damper cover and balance shaft driven gear are aligned. TEXT IN ILLUSTRATION *1 Alignment Mark If the alignment marks are not aligned, realign them. Place a wrench on the rear cutout part of the No. 2 balance shaft and fix the shaft in place. TEXT IN ILLUSTRATION *1 Driven Gear *2 Damper Cover *3 Alignment Mark Rotate the balance shaft driven gear of the No. 1 balance shaft counterclockwise to align the alignment mark of the balance shaft driven gear with the alignment mark of the balance shaft damper cover. Install the engine balancer to the stiffening crankcase with the 3 bolts and tighten the bolts in the sequence shown in the illustration. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
INSTALL STIFFENING CRANKCASE ASSEMBLY Rotate the crankshaft clockwise so that the crankshaft key is at the position 270° from the bottom as shown in the illustration. TEXT IN ILLUSTRATION *1 Key Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal Dimension Area Specified Condition Continuous Line 2.5 to 3.5 mm (0.0984 to 0.138 in.) Dashed Line 7.0 to 9.0 mm (0.276 to 0.354 in.) wide and 2.5 to 3.5 mm (0.0984 to 0.138 in.) thick Application length A 28 mm (1.10 in.) TEXT IN ILLUSTRATION *1 Seal Packing *2 Continuous Line *3 Dashed Line Stiffening Crankcase Cylinder Block NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Do not apply oil for at least 4 hours after the installation. Do not start the engine for at least 4 hours after the installation. Check that the rear cutouts are as shown in the illustration. TEXT IN ILLUSTRATION *1 Cutout Clean the bolts and their installation holes. Apply adhesive to 3 threads or more at the end of bolt A. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Temporarily install the stiffening crankcase with the 11 bolts. Bolt Length Item Length Bolt A 65 mm (2.56 in.) Bolt B 35 mm (1.38 in.) Bolt C 125 mm (4.92 in.) Bolt D 165 mm (6.50 in.) HINT: Apply adhesive to bolt A before installing it Tighten the 11 bolts in the sequence shown in the illustration to install the stiffening crankcase. for bolt A Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) except bolt A Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSTALL NO. 1 OIL PAN BAFFLE PLATE Install the oil pan baffle plate and uniformly tighten the 5 bolts in several steps in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL OIL STRAINER SUB-ASSEMBLY Apply a light coat of engine oil to a new gasket. TEXT IN ILLUSTRATION *1 Protrusion Align the protrusion of the gasket with the cutout of the oil strainer and install the gasket to the oil strainer. Install the oil strainer with the 3 bolts in several steps in the sequence shown in the illustration. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL OIL PAN SUB-ASSEMBLY Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing. Do not apply oil for at least 4 hours after the installation. Do not start the engine for at least 4 hours after the installation. Install the oil pan with the 11 bolts and 2 nuts in several steps in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) HINT: Bolt A and nut A are tightened twice.
INSTALL OIL FILTER ELEMENT. Refer to «REPLACEMENT [05/2013 - ] - Step 4»(ref-615225-S38746355212014050900000)
INSTALL REAR ENGINE OIL SEAL See step 1
INSTALL CYLINDER BLOCK WATER JACKET SPACER Install the water jacket spacer to the cylinder block.
INSTALL CYLINDER HEAD GASKET See step 1
INSTALL CYLINDER HEAD SUB-ASSEMBLY See step 2
SET CAMSHAFT TIMING GEAR ASSEMBLY See step 4
INSTALL CAMSHAFT BEARING CAP SETTING RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Using a plastic-faced hammer, tap in 10 new ring pins to the camshaft housing. Standard protrusion height 2.7 to 3.3 mm (0.106 to 0.130 in.) TEXT IN ILLUSTRATION *1 Protrusion Height
INSTALL CAMSHAFT HOUSING STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Using a plastic-faced hammer, tap in 2 new straight pins to the camshaft housing. Standard protrusion height 5.0 to 7.0 mm (0.197 to 0.276 in.) TEXT IN ILLUSTRATION *1 Protrusion Height
INSTALL CAMSHAFT HOUSING STUD BOLT NOTE: If a stud bolt is deformed or its threads are damaged, replace it. Using an E8 "TORX" socket wrench, install the stud bolt. Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf)
INSTALL NO. 1 CAMSHAFT BEARING Clean the No. 1 camshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper Install the camshaft bearing to the No. 1 camshaft bearing cap. Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the camshaft bearing edge. Dimension A - B or B - A 0 to 0.7 mm (0 to 0.0276 in.)
INSTALL NO. 2 CAMSHAFT BEARING Clean the No. 2 camshaft bearing. TEXT IN ILLUSTRATION *1 Vernier Caliper Install the camshaft bearing to the camshaft housing. Using a vernier caliper, measure the distance between the camshaft housing edge and the camshaft bearing edge. Standard distance 1.15 to 1.85 mm (0.0453 to 0.0728 in.)
INSTALL OIL CONTROL VALVE FILTER Install the oil control valve filter to the No. 1 camshaft bearing cap.
INSTALL CAMSHAFT See step 10
INSTALL CAMSHAFT BEARING CAP See step 11
INSTALL VALVE STEM CAP See step 3
INSTALL VALVE LASH ADJUSTER ASSEMBLY See step 5
INSTALL VALVE ROCKER ARM SUB-ASSEMBLY See step 6
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY See step 12
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY See step 13
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY See step 14
INSTALL CRANKSHAFT TIMING SPROCKET Install the crankshaft timing sprocket to the crankshaft.
ADD ENGINE OIL See step 15
SET NO. 1 CYLINDER TO TDC/COMPRESSION See step 16
INSTALL NO. 1 CHAIN VIBRATION DAMPER See step 17
INSTALL CHAIN SUB-ASSEMBLY See step 18
INSTALL CHAIN TENSIONER SLIPPER See step 19
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY See step 20
INSTALL TIMING CHAIN GUIDE See step 21
CHECK NO. 1 CYLINDER TO TDC/COMPRESSION See step 22
INSTALL TIMING CHAIN COVER PLATE Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL TIMING CHAIN COVER TIGHT PLUG Using a 14 mm hexagon wrench, install a new gasket and plug. Torque: 30 N*m (306 kgf*cm, 20 ft.*lbf)
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 1»(ref-615225-S09042660382014050900000)
INSTALL ENGINE MOUNTING BRACKET RH. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 2»(ref-615225-S09042660382014050900000)
INSTALL TIMING CHAIN COVER OIL SEAL See step 1
INSTALL SPARK PLUG TUBE GASKET. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 7»(ref-615225-S09042660382014050900000)
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 8»(ref-615225-S09042660382014050900000)
INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the crankshaft pulley. Using SST, hold the crankshaft pulley and install the pulley bolt. SST: 09213-54015 SST: 09330-00021 Torque: 260 N*m (2651 kgf*cm, 192 ft.*lbf) HINT: Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)
INSTALL CRANKSHAFT POSITION SENSOR. Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S27052593842014050900000)
INSTALL WATER INLET HOUSING Install a new gasket and the water inlet housing with the 4 bolts and nut. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSTALL ENGINE WATER PUMP ASSEMBLY. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 1»(ref-615227-S39769214092014050900000)
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 2»(ref-615227-S39769214092014050900000)
INSTALL THERMOSTAT. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 1»(ref-615227-S04767882412014050900000)
INSTALL WATER INLET. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 2»(ref-615227-S04767882412014050900000)
INSTALL NO. 1 WATER BY-PASS PIPE Install a new gasket and the water by-pass pipe with the 2 nuts and bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL SEPARATOR CASE Apply a light coat of engine oil to a new gasket. Install the gasket to the separator case. Install the separator case with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL PCV CASE Apply seal packing in a continuous line as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter 2.5 to 3.5 mm (0.0984 to 0.138 in.) TEXT IN ILLUSTRATION *1 Seal Packing NOTE: Remove any oil from the contact surface. Install the PCV case within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Install the PCV case, and then install the 8 bolts and 2 nuts in the order shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: Bolt A is tightened twice.
INSTALL PCV VALVE. Refer to «INSTALLATION [05/2013 - 01/2014] - Step 1»(ref-615251-S31600646192014050900000)
INSTALL CAMSHAFT POSITION SENSOR (for Intake Side). Refer to «INSTALLATION [05/2013 - ] - Step 2»(ref-615228-S05338824542014050900000)
INSTALL CAMSHAFT POSITION SENSOR (for Exhaust Side). Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S05338824542014050900000)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side). Refer to «INSTALLATION [05/2013 - ] - Step 2»(ref-615228-S04108428122014050900000)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side). Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S04108428122014050900000)
INSTALL OIL FILLER CAP SUB-ASSEMBLY Install a new gasket to the oil filler cap. Install the oil filler cap to the cylinder head.
INSTALL SPARK PLUG. Refer to «INSTALLATION [05/2013 - ] - Step 1»(ref-615228-S42311741022014050900000)
INSTALL ENGINE COVER JOINT Install the 3 joints. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Engine Mechanical (Service Information): Diagnosis Scion tC II рестайлинг